Control arm assembly

Abstract

A control arm assembly includes a control arm including a knuckle support member having an upper surface, a lower surface, a proximal end portion and a distal end portion. The upper surface includes a recessed portion extending from the distal end portion toward the proximal end portion. The distal end portion includes a collar defining an aperture for receiving a housing of a ball joint. The control arm assembly also includes a protective cap attached to the knuckle support member. The protective cap overlies the recessed portion of the upper surface of the knuckle support member.

What is claimed is: 
     
       1. A control arm assembly comprising:
 a control arm comprising a knuckle support member, the knuckle support member comprising an upper surface, a lower surface, a proximal end portion and a distal end portion, the upper surface including a recessed portion extending from the distal end portion toward the proximal end portion, the distal end portion comprising a collar defining an aperture; 
 a ball joint assembly comprising a ball joint and a boot, the ball joint comprising a housing received within the aperture defined by the collar of the distal end portion of the knuckle support member, the boot being attached to the ball joint and disposed in surrounding relationship with the housing of the ball joint; and 
 a protective cap attached to the knuckle support member, the protective cap comprising an annular rim defining an opening; wherein 
 the protective cap overlies the recessed portion of the upper surface of the knuckle support member; and 
 the boot extends through the opening defined by the annular rim of the protective cap, the annular rim being disposed in sealing engagement with the boot. 
 
     
     
       2. The control arm assembly of  claim 1 , wherein:
 the protective cap and the knuckle support member cooperate to define a cavity, the recessed portion of the upper surface of the knuckle support member partially defining the cavity; and 
 the collar extends above the upper surface of the knuckle support member and is positioned within the cavity. 
 
     
     
       3. The control arm assembly of  claim 2 , wherein:
 the annular rim of the protective cap is positioned above the collar of the distal end portion of the knuckle support member of the control arm. 
 
     
     
       4. The control arm assembly of  claim 3 , wherein:
 the housing of the ball joint engages the collar of the distal end portion of the knuckle support member in an interference fit; 
 the protective cap comprises a perimeter; and 
 the protective cap is in contacting engagement with the upper surface of the knuckle support member along the entire perimeter of the protective cap; and 
 the sealing engagement of the annular rim of the protective cap with the boot cooperates with the engagement of the housing with the collar in an interference fit and with the contacting engagement of the protective cap with the upper surface of the knuckle support member to at least substantially seal the cavity defined by the protective cap and the knuckle support member. 
 
     
     
       5. The control arm assembly of  claim 3 , wherein:
 the boot comprises a lower end; 
 the annular rim of the protective cap engages the boot above the lower end of the boot; and 
 the protective cover is formed from a plastic material as a unitary structure. 
 
     
     
       6. The control arm assembly of  claim 2 , wherein:
 the protective cap further comprises a mount boss positioned within the cavity defined by the protective cap and the knuckle support member. 
 
     
     
       7. The control arm assembly of  claim 6 , further comprising:
 a male fastener; wherein 
 the knuckle support member defines at least one fastener-receiving aperture; 
 the mount boss of the protective cap defines a threaded aperture; and 
 the male fastener extends through the at least one fastener-receiving aperture defined by the knuckle support member and is threaded into the threaded aperture defined by the mount boss of the protective cap. 
 
     
     
       8. The control arm assembly of  claim 1 , wherein:
 the boot comprises a lower end; and 
 the annular rim of the protective cap engages the boot above the lower end of the boot. 
 
     
     
       9. The control arm assembly of  claim 1 , wherein:
 the protective cap comprises a plastic material. 
 
     
     
       10. The control arm assembly of  claim 1 , wherein:
 the protective cap comprises an upper surface; and 
 the upper surface of the protective cap has a generally convex shape, as the protective cap is viewed in transverse cross-section, at least at a location proximal of, and adjacent to, the annular rim of the protective cap. 
 
     
     
       11. The control arm of  claim 1 , wherein:
 the protective cap comprises a proximal end, a distal end, and a longitudinal centerline axis; and 
 the annular rim is positioned adjacent to the distal end of the protective cap. 
 
     
     
       12. The control arm assembly of  claim 1 , wherein:
 the protective cap is formed from a plastic material as a unitary structure; and 
 the opening defined by the annular rim of the protective cap is aligned with the aperture defined by the collar of the distal end portion of the knuckle support member. 
 
     
     
       13. A control arm assembly comprising:
 a control arm comprising a knuckle support member, the knuckle support member comprising an upper surface, a lower surface, a proximal end portion and a distal end portion, the upper surface including a recessed portion extending from the distal end portion toward the proximal end portion, the distal end portion comprising a collar defining an aperture; and 
 a protective cap attached to the knuckle support member, the protective cap being formed from a plastic material as a unitary structure, the protective cap comprising an annular rim defining an opening; wherein 
 the protective cap overlies the recessed portion of the upper surface of the knuckle support member; 
 the opening defined by the annular rim of the protective cap is aligned with the aperture defined by the collar of the distal end portion of the knuckle support member; 
 the protective cap comprises a perimeter; and 
 the protective cap is in contacting engagement with the upper surface of the knuckle support member along the entire perimeter of the protective cap. 
 
     
     
       14. The control arm assembly of  claim 13 , further comprising:
 a ball joint assembly comprising a ball joint and a boot, the ball joint comprising a housing received within the aperture defined by the collar of the distal end portion of the knuckle support member of the control arm, the boot being attached to the ball joint and disposed in surrounding relationship with the housing; wherein 
 the boot extends through the opening defined by the annular rim of the protective cap; 
 the boot comprises an elastomeric material; and 
 the annular rim of the protective cap is disposed in sealing engagement with the boot. 
 
     
     
       15. The control arm assembly of  claim 14 , wherein:
 the protective cap comprises a proximal end, a distal end, and a longitudinal centerline axis; 
 the annular rim is positioned adjacent to the distal end of the protective cap; and 
 the upper surface of the protective cap has a generally convex shape, as the protective cap is viewed in transverse cross-section, at least at a location proximal of, and adjacent to, the annular rim of the protective cap. 
 
     
     
       16. A vehicle comprising:
 a front wheel; 
 a knuckle coupled with the front wheel; 
 a frame; and 
 a control arm assembly pivotally coupled with the knuckle and with the frame; wherein 
 the control arm assembly comprises a control arm and a ball joint assembly pivotally coupling the control arm with the knuckle; 
 the control arm comprises a knuckle support member and the control arm assembly further comprises a protective cap attached to the knuckle support member; 
 the knuckle support member comprises an upper surface, a lower surface, a proximal end portion and a distal end portion, the upper surface including a recessed portion extending from the distal end portion toward the proximal end portion, the distal end portion comprising a collar defining an aperture; 
 the ball joint assembly comprises a ball joint and a boot, the ball joint comprising a stem attached to the knuckle, and a housing received within the aperture defined by the collar of the distal end portion of the knuckle support member; 
 the protective cap overlies the recessed portion of the upper surface of the knuckle support member and comprises an annular rim defining an opening aligned with the aperture defined by the collar of the distal end portion of the knuckle support member; and 
 the boot extends through the opening defined by the annular rim of the protective cap, the annular rim being disposed in sealing engagement with the boot. 
 
     
     
       17. The vehicle of  claim 16 , wherein:
 the protective cap is formed from a plastic material as a unitary structure. 
 
     
     
       18. The vehicle of  claim 17 , wherein:
 the protective cap comprises a proximal end, a distal end, and a longitudinal centerline axis; 
 the annular rim is positioned adjacent to the distal end of the protective cap; 
 the protective cap slopes generally downwardly from the proximal end toward the annular rim along the longitudinal centerline axis; and 
 the upper surface of the protective cap has a generally convex shape, as the protective cap is viewed in transverse cross-section, at least at a location proximal of, and adjacent to, the annular rim of the protective cap. 
 
     
     
       19. The vehicle of  claim 16 , wherein:
 the protective cap and the knuckle support member cooperate to define a cavity, the recessed portion of the upper surface of the knuckle support member partially defining the cavity. 
 
     
     
       20. The vehicle of  claim 19 , wherein:
 the boot comprises a lower end; 
 the annular rim of the protective cap engages the boot above the lower end of the boot; 
 the collar of the distal end portion of the knuckle support member extends into the cavity; 
 the housing of the ball joint engages the collar in an interference fit; and 
 the annular rim of the protective cap is positioned above the collar.